IP Library › Granted Patent US 6,892,104
Granted Patent B2
US 6,892,104 · App. 09/799,859 · Granted May 10, 2005

System and method for manufacturing products according to customer orders

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Quick Facts
Patent No.
US 6,892,104
App. No.
09/799,859
Granted
May 10, 2005
Kind
B2
Abstract

A build cell for manufacturing products according to customer orders includes a build station at which components are assembled according to a customer order to form an assembled product. The build cell also includes a burn station at which the assembled product is configured and tested to form a configured product. In addition, the build cell includes a finishing station at which the configured product is inspected to produce a finished product. A transportation device transports the finished product from the build cell to a transportation system for delivery to a boxing facility, such that the product is assembled, configured, tested, and inspected in the build cell and packaged at the boxing facility. In an illustrative embodiment, the product is a computer, the components include hardware components, which are assembled at the build station, and software is installed at the burn station.

Claims (46)

1. A build cell for manufacturing products according to customer orders, the build cell comprising:

a first side, a second side adjacent to the first side, and a third side adjacent to the second side;

a build station at which components are assembled according to a customer order to form an assembled product, the build station being situated at the first side;

a burn station at which the assembled product is configured according to the customer order and tested to form a configured product, the burn station being situated at the second side;

a finishing station at which the configured product is inspected to produce a finished product, the finishing station being situated at the third side;

an open area of floor between the first and third sides, the open area dimensioned to accommodate at least one human operator

fourth side adjacent to the third side; and

printer at the fourth side for printing identifying information for the product on an asset tag to be applied to the configured product according to the customer order.

2. The build cell of claim 1 , wherein:

the components comprise hardware that was specified by the customer order,

the configured product includes software that was specified by the customer order; and

the finished product comprises an operational computer.

3. The build cell of claim 1 further comprising:

a transportation device that transports the finished product from the build cell to a transportation system for delivery to a boxing facility whereby the finished product is packaged.

4. The build cell of claim 3 , wherein the transportation device is located below a transportation system that includes an incoming conveyor and an outgoing conveyor that are aligned generally vertically to conserve space within a manufacturing facility.

5. The build cell of claim 3 , wherein the finishing station further comprises:

a finishing shelf;

a finishing conveyor that transports the configured product to the finishing shelf; and

an exit conveyor that transports the finished product from the finishing shelf to a staging area for removal from the build cell.

6. The build cell of claim 5 , wherein the finishing conveyor and the exit conveyor are aligned generally vertically to conserve space within a manufacturing facility.

7. The build cell of claim 1 , further comprising sufficient floor space to accommodate at least four human operators.

8. A build cell for manufacturing products according to customer orders, the build cell comprising:

build station at which components are assembled to form an assembled product;

burn station at which the assembled product is configured according to the customer order and tested to form a configured product, the burn station being generally aligned with a corresponding burn station in a first adjacent build cell;

transportation device that transports the assembled product to the burn station, the transportation device being situated between the build cell and the first adjacent build cell to also service the corresponding burn station in the first adjacent build cell, wherein the transportation device comprises:

a shelf that moves vertically to transport a tote to the build station; and

the transportation device horizontally movable and the shelf vertically movable to transport the assembled product to the burn station.

9. The build cell of claim 8 , wherein the transportation device also transports the components from an incoming conveyor to the build station.

10. The build cell of claim 8 , wherein the transportation device also removes a finished product from the build cell.

11. The build cell of claim 8 , wherein the build cell comprises an open area of floor dimensioned to accommodate an operator who manually transports the assembled product as required.

12. The build cell of claim 8 , further comprising a display that depicts a performance rating for the build cell, relative to other build cells in a manufacturing facility.

13. The build cell of claim 8 , wherein the burn station comprises:

a matrix of compartments, including a plurality of burn compartments and at least one compartment that receives assembled products destined for an electromechanical repair (EMR) station.

14. The build cell of claim 8 , wherein the burn station comprises:

a matrix of compartments, including a plurality of burn compartments and at least one compartment that receives assembled products from an electromechanical repair (EMR) station.

15. The build cell of claim 8 , further comprising a barcode scanner that obtains information from one or more of the components that are assembled.

16. The build cell of claim 8 , wherein the product comprises:

a data processing system that was ordered with specified hardware and software components, and the data processing system is tested and cleaned at a finishing station.

17. A build cell for manufacturing products according to customer orders, the build cell comprising:

build station at which components are assembled to form an assembled product, the build cell including a quick-test station and an open area of floor dimensioned to accommodate an operator;

burn station at which the assembled product is configured according to the customer order and tested to form a configured product, the burn station being generally aligned with a corresponding burn station in a first adjacent build cell; and

transportation device that transports the assembled product to the burn station, the transportation device being situated between the build cell and the first adjacent build cell to also service the corresponding burn station in the first adjacent build cell and wherein:

the transportation device automatically transports the assembled product to the quick-test station in response to detecting the assembled product at an exit stage of the build station;

the transportation device automatically transports the assembled product from the quick-test station to the burn station in response to a first signal from the operator;

the transportation device automatically transports the configured product from the burn station to a finishing station in response to a second signal from the operator; and

the transportation device automatically transports the finished product from an exit conveyor to an outgoing conveyor in response to detecting a finished product at an exit stage of the finishing station without the operator manually lifting the assembled product.

Assignments (14)
RELEASE OF SECURITY INTEREST IN PATENTS PREVIOUSLY RECORDED AT REEL/FRAME (053546/0001) Recorded Jun 23, 2022
From: THE BANK OF NEW YORK MELLON TRUST COMPANY, N.A., AS NOTES COLLATERAL AGENT
To: DELL MARKETING L.P. (ON BEHALF OF ITSELF AND AS SUCCESSOR-IN-INTEREST TO CREDANT TECHNOLOGIES, INC.); DELL INTERNATIONAL L.L.C.; DELL PRODUCTS L.P.; DELL USA L.P.; EMC CORPORATION; DELL MARKETING CORPORATION (SUCCESSOR-IN-INTEREST TO FORCE10 NETWORKS, INC. AND WYSE TECHNOLOGY L.L.C.); EMC IP HOLDING COMPANY LLC
Reel/Frame 071642/0001 →
RELEASE OF SECURITY INTEREST IN PATENTS PREVIOUSLY RECORDED AT REEL/FRAME (045455/0001) Recorded May 20, 2022
From: THE BANK OF NEW YORK MELLON TRUST COMPANY, N.A., AS NOTES COLLATERAL AGENT
To: DELL MARKETING CORPORATION (SUCCESSOR-IN-INTEREST TO ASAP SOFTWARE EXPRESS, INC.); DELL MARKETING L.P. (ON BEHALF OF ITSELF AND AS SUCCESSOR-IN-INTEREST TO CREDANT TECHNOLOGIES, INC.); DELL USA L.P.; DELL INTERNATIONAL L.L.C.; DELL PRODUCTS L.P.; DELL MARKETING CORPORATION (SUCCESSOR-IN-INTEREST TO FORCE10 NETWORKS, INC. AND WYSE TECHNOLOGY L.L.C.); EMC CORPORATION (ON BEHALF OF ITSELF AND AS SUCCESSOR-IN-INTEREST TO MAGINATICS LLC); EMC IP HOLDING COMPANY LLC (ON BEHALF OF ITSELF AND AS SUCCESSOR-IN-INTEREST TO MOZY, INC.); SCALEIO LLC
Reel/Frame 061753/0001 →
RELEASE OF SECURITY INTEREST IN PATENTS PREVIOUSLY RECORDED AT REEL/FRAME (040136/0001) Recorded Apr 26, 2022
From: THE BANK OF NEW YORK MELLON TRUST COMPANY, N.A., AS NOTES COLLATERAL AGENT
To: DELL MARKETING CORPORATION (SUCCESSOR-IN-INTEREST TO ASAP SOFTWARE EXPRESS, INC.); DELL MARKETING L.P. (ON BEHALF OF ITSELF AND AS SUCCESSOR-IN-INTEREST TO CREDANT TECHNOLOGIES, INC.); DELL USA L.P.; DELL INTERNATIONAL L.L.C.; DELL PRODUCTS L.P.; DELL MARKETING CORPORATION (SUCCESSOR-IN-INTEREST TO FORCE10 NETWORKS, INC. AND WYSE TECHNOLOGY L.L.C.); EMC CORPORATION (ON BEHALF OF ITSELF AND AS SUCCESSOR-IN-INTEREST TO MAGINATICS LLC); EMC IP HOLDING COMPANY LLC (ON BEHALF OF ITSELF AND AS SUCCESSOR-IN-INTEREST TO MOZY, INC.); SCALEIO LLC
Reel/Frame 061324/0001 →
RELEASE OF SECURITY INTEREST Recorded Nov 3, 2021
From: CREDIT SUISSE AG, CAYMAN ISLANDS BRANCH
To: DELL USA L.P.; ASAP SOFTWARE EXPRESS, INC.; AVENTAIL LLC; CREDANT TECHNOLOGIES, INC.; DELL INTERNATIONAL, L.L.C.; DELL MARKETING L.P.; DELL PRODUCTS L.P.; DELL SOFTWARE INC.; DELL SYSTEMS CORPORATION; EMC CORPORATION; EMC IP HOLDING COMPANY LLC; FORCE10 NETWORKS, INC.; MAGINATICS LLC; MOZY, INC.; SCALEIO LLC; WYSE TECHNOLOGY L.L.C.
Reel/Frame 058216/0001 →
SECURITY AGREEMENT Recorded Mar 21, 2019
From: CREDANT TECHNOLOGIES, INC.; DELL INTERNATIONAL L.L.C.; DELL MARKETING L.P.; DELL PRODUCTS L.P.; DELL USA L.P.; EMC CORPORATION; FORCE10 NETWORKS, INC.; WYSE TECHNOLOGY L.L.C.; EMC IP HOLDING COMPANY LLC
To: THE BANK OF NEW YORK MELLON TRUST COMPANY, N.A.
Reel/Frame 049452/0223 →
SECURITY AGREEMENT Recorded Sep 21, 2016
From: ASAP SOFTWARE EXPRESS, INC.; AVENTAIL LLC; CREDANT TECHNOLOGIES, INC.; DELL USA L.P.; DELL INTERNATIONAL L.L.C.; DELL MARKETING L.P.; DELL PRODUCTS L.P.; DELL SOFTWARE INC.; DELL SYSTEMS CORPORATION; EMC CORPORATION; EMC IP HOLDING COMPANY LLC; FORCE10 NETWORKS, INC.; MAGINATICS LLC; MOZY, INC.; SCALEIO LLC; SPANNING CLOUD APPS LLC; WYSE TECHNOLOGY L.L.C.
To: THE BANK OF NEW YORK MELLON TRUST COMPANY, N.A., AS NOTES COLLATERAL AGENT
Reel/Frame 040136/0001 →
SECURITY AGREEMENT Recorded Sep 21, 2016
From: ASAP SOFTWARE EXPRESS, INC.; AVENTAIL LLC; CREDANT TECHNOLOGIES, INC.; DELL USA L.P.; DELL INTERNATIONAL L.L.C.; DELL MARKETING L.P.; DELL PRODUCTS L.P.; DELL SOFTWARE INC.; DELL SYSTEMS CORPORATION; EMC CORPORATION; EMC IP HOLDING COMPANY LLC; FORCE10 NETWORKS, INC.; MAGINATICS LLC; MOZY, INC.; SCALEIO LLC; SPANNING CLOUD APPS LLC; WYSE TECHNOLOGY L.L.C.
To: CREDIT SUISSE AG, CAYMAN ISLANDS BRANCH, AS COLLATERAL AGENT
Reel/Frame 040134/0001 →
RELEASE OF SECURITY INTEREST Recorded Sep 14, 2016
From: BANK OF NEW YORK MELLON TRUST COMPANY, N.A., AS COLLATERAL AGENT
To: DELL MARKETING L.P.; ASAP SOFTWARE EXPRESS, INC.; APPASSURE SOFTWARE, INC.; COMPELLENT TECHNOLOGIES, INC.; CREDANT TECHNOLOGIES, INC.; DELL INC.; DELL PRODUCTS L.P.; DELL USA L.P.; DELL SOFTWARE INC.; FORCE10 NETWORKS, INC.; PEROT SYSTEMS CORPORATION; SECUREWORKS, INC.; WYSE TECHNOLOGY L.L.C.
Reel/Frame 040065/0618 →
RELEASE OF SECURITY INTEREST Recorded Sep 14, 2016
From: BANK OF AMERICA, N.A., AS COLLATERAL AGENT
To: DELL MARKETING L.P.; ASAP SOFTWARE EXPRESS, INC.; APPASSURE SOFTWARE, INC.; COMPELLENT TECHNOLOGIES, INC.; CREDANT TECHNOLOGIES, INC.; DELL INC.; DELL PRODUCTS L.P.; DELL USA L.P.; DELL SOFTWARE INC.; FORCE10 NETWORKS, INC.; PEROT SYSTEMS CORPORATION; SECUREWORKS, INC.; WYSE TECHNOLOGY L.L.C.
Reel/Frame 040040/0001 →
RELEASE OF SECURITY INTEREST Recorded Sep 13, 2016
From: BANK OF AMERICA, N.A., AS ADMINISTRATIVE AGENT
To: DELL MARKETING L.P.; ASAP SOFTWARE EXPRESS, INC.; APPASSURE SOFTWARE, INC.; COMPELLANT TECHNOLOGIES, INC.; CREDANT TECHNOLOGIES, INC.; DELL INC.; DELL PRODUCTS L.P.; DELL USA L.P.; DELL SOFTWARE INC.; FORCE10 NETWORKS, INC.; PEROT SYSTEMS CORPORATION; SECUREWORKS, INC.; WYSE TECHNOLOGY L.L.C.
Reel/Frame 040065/0216 →
PATENT SECURITY AGREEMENT (TERM LOAN) Recorded Jan 2, 2014
From: DELL INC.; APPASSURE SOFTWARE, INC.; ASAP SOFTWARE EXPRESS, INC.; BOOMI, INC.; COMPELLENT TECHNOLOGIES, INC.; CREDANT TECHNOLOGIES, INC.; DELL MARKETING L.P.; DELL PRODUCTS L.P.; DELL SOFTWARE INC.; DELL USA L.P.; FORCE10 NETWORKS, INC.; GALE TECHNOLOGIES, INC.; PEROT SYSTEMS CORPORATION; SECUREWORKS, INC.; WYSE TECHNOLOGY L.L.C.
To: BANK OF AMERICA, N.A., AS COLLATERAL AGENT
Reel/Frame 031899/0261 →
PATENT SECURITY AGREEMENT (ABL) Recorded Jan 2, 2014
From: DELL INC.; APPASSURE SOFTWARE, INC.; ASAP SOFTWARE EXPRESS, INC.; BOOMI, INC.; COMPELLENT TECHNOLOGIES, INC.; CREDANT TECHNOLOGIES, INC.; DELL MARKETING L.P.; DELL PRODUCTS L.P.; DELL SOFTWARE INC.; DELL USA L.P.; FORCE10 NETWORKS, INC.; GALE TECHNOLOGIES, INC.; PEROT SYSTEMS CORPORATION; SECUREWORKS, INC.; WYSE TECHNOLOGY L.L.C.
To: BANK OF AMERICA, N.A., AS ADMINISTRATIVE AGENT
Reel/Frame 031898/0001 →
PATENT SECURITY AGREEMENT (NOTES) Recorded Jan 2, 2014
From: APPASSURE SOFTWARE, INC.; ASAP SOFTWARE EXPRESS, INC.; BOOMI, INC.; COMPELLENT TECHNOLOGIES, INC.; CREDANT TECHNOLOGIES, INC.; DELL INC.; DELL MARKETING L.P.; DELL PRODUCTS L.P.; DELL SOFTWARE INC.; DELL USA L.P.; FORCE10 NETWORKS, INC.; GALE TECHNOLOGIES, INC.; PEROT SYSTEMS CORPORATION; SECUREWORKS, INC.; WYSE TECHNOLOGY L.L.C.
To: BANK OF NEW YORK MELLON TRUST COMPANY, N.A., AS FIRST LIEN COLLATERAL AGENT
Reel/Frame 031897/0348 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Dec 31, 2001
From: GRAHAM, MICHAEL T.
To: DELL PRODUCTS L.P.
Reel/Frame 012415/0141 →